Experimental investigation on the vibrational and fluid dynamics behaviour of a turbocharger compressor in the transition to surge operation

High-speed dynamic centrifugal compressors are widely used both in the modern internal combustion engine design and in advanced pressurized cycles and innovative plant layouts as fuel cell systems. Surge strongly limits the stable operating region of centrifugal compressors in low mass flow rate conditions especially during fast transients. Therefore, it is of great importance to investigate transient system dynamic response of compressor surge evolution and early detection of incipient compressor surge. A specific experimental investigation on compressor surge was carried out at the University of Genoa turbocharger test facility and results are presented and analysed in this paper. The activity consists of steady state and transient measurements used to characterize and identify compressor behaviour in correspondence of surge inception conditions. The frequency and time frequency data analysis have been applied on inflow pressure, anemometric and vibrational signals to identify their contents and so to be able to classify compressor operation as stable or unstable. Synchronous averages performed in the time domain have been identified as a suitable algorithmic tool to detect incipient surge conditions. Anemometric signal analysis allowed to identify intermitting phenomena in deep surge conditions may be related to the rise of a rotation stall condition. The obtained results provide original diagnostic and predictive methods to be integrated in a monitoring system capable of preventing surge and extending compressor operating range, performance and reliability to allow the integration with the other plant components.